Thermally responsive electrical switches



Nov. 17, 1964 R. H. LADD ETAL 3,157,768

THERMALLY RESPONSIVE ELECTRICAL SWITCHES mwa/rams.-

Raamr H. 400, Aofr M. maf/V, 5 75L@ "Q Wr n Nov; 17, 1964 a. H. LADD ETAL 3,157,768

THERMALLY RESPONSIVE ELECTRICAL SWITCHES Filed Feb. 9, 1962 3 Sheets-Sheet 2 United States Patent O 3,157,7ss Tnmniviaaav nnsroNsrvs enactment swircnas This invention relates to thermally responsive electrical switches and more particularly to mounting brackets or flanges therefor.

Among the several objects of this invention may be noted the provision of thermally responsive electrical switches and detachable mounting flanges therefor; the provision of such switches and mounting flanges which can be quickly and easily detachably secured together; the provision of such devices wherein one electrical switch can be employed with and detachably connected to any one of several different types of interchangeable mounting flanges; and the provision of electrical switches and detachable mounting ilanges therefor which are economical to manufacture and which can be quickly and economically assembled.

Other objects will be in part apparent and in part pointed out hereinafter.

The invention accordingly comprises the elements and combinations of elements, features of construction, and arrangements of parts which will be exemplified in the structures hereinafter described, and the scope of the application of which will be indicated in the following claims.

In the accompanying drawings, in which several of the various possible embodiments of the invention are illustrated:

FIG. l is a sectional view of an electrical switch and mounting bracket or ange embodying the invention;

FIG. 2 is a bottom View of the switch and mounting flange shown in FIG. l on a reduced scale and with the support omitted for purposes of clarity of illustration;

FIG. 3 is an enlarged fragmentary elevational view of a portion of the switch housing showing a locking tab according to the present invention;

FG. 4 is an exploded elevational View illustrating a second embodiment according to the present invention;

FIG. 5 is a bottom plan View of the parts shown in FIG. 4 in assembled, locked relation;

FTG. 6 is a fragmentary elevational View with certain parts in section, illustrating a third embodiment according to the present invention;

FiG. 7 is a fragmentary elevational View illustrating a fourth embodiment according to the present invention;

FIG. 8 is a view taken online 3 8 of FTG. 7; and,

FiGS. 9 and l0 respectively are fragmentary elevational views showing a developed inside edge of a mounting flange at a part thereof around the thermostat housing receiving opening therein respectively according to a fifth and sixth embodiment of the present invention.

Similar reference characters indicate corresponding parts throughout the` several views of the drawings.

Dimensions of certain of the parts as shown in the drawings may have been modified and/or exaggerated for the purposes of clarity of illustration.'

it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein Iis for the purpose of description and not of limitation.

Thermally responsive electrical switches, particularly those of the snapacting disc type have heretofore been made in a variety of housing configurations and with diilerent types of mounting brackets or flanges to meet specific application requirements, the mounting brackets or flanges generally differing mainly in dimension, configuration, number of bolt receiving holes, etc. Such mounting brackets or flanges heretofore have generally been formed integrally with or permanently secured to the switch housing. This has the drawback of requiring the manufacture and inventory maintenance of a large variety of therniostats or switches which in many cases differ only in the type of mounting brackets required for specific applications. The present invention proposes to obviate or at least minimize this drawback by providing a plurality of different interchangeable detachable mounting,l brackets or flanges, any one of which can quickly and easily be detachably connected to a standard type of thermostat. Thus, according to the invention, one or more standard types of thermostats or electrical switches can conveniently and economically be mass produced and supplied with a kit of assorted types of interchangeable mounting flanges each of which can be quickly and easily detachabiy connected to the thermostat so as to mount the thermostat on a support in thermal juxtaposition to a substance or device whose temperature is to be sense l. The present invention also simpliiies thermostat identication, permits maintaining an economically smaller inventory and provides increased versatility of application for the thermally responsive switches.

Referring now to FIG. l of the drawings an exemplary switch construction in the form of an automatically resetting, thermally responsive snap-acting switch 1G is shown which may be employed in the practice of the present invention. Switch lil is of the type shown and described in US. Patent 2,824,l94 to l. O. Moorhead issued on February 18, 1958, to which patent reference may be had for details of construction. Electrical switch l@ includes a two-part housing l2 and ill. Housing part i2 is formed of an electrical insulating material such as one ofthe customary molded plastics. A pair of terminals i6 and l are supported by the housing member 12 in any suitable manner. ly way of example, casing member l2 may be molded about these terminals. Each of terminals lo and l leads to the exterior of the casing member l2 whereby it may be externally connected in an electrical circuit. y

Terminals lo and l provide contacts or contact forming portions Zi? and 22, each of which may be respectively provided with layers or portions 24 and 26, formed of a material havinf7 a high electrical conductivity such as silver and tue like. Terminals lo and i8 except for l yers 2d and 26, may be formed of any suitable electrically conductive material such as for example brass, ivionel or copper. An electrically conductive bridging contact member 3d formed, for example of brass, Monel or copper, is disposed adjacent contacts 2d and 26. The contact forming surface of contact member 3i) which cooperates with the adjacent surface of contacts 2d and 26 may be formed of a layer or portion 32 of silver or other contact alloy which is suitably bonded to the remainder of contact member 3l?. Contact member 3% is engageable and disengageable with both of contacts 24 and 2o to electrically connect and disconnect contacts 2d and The upper surface of bridging contact member Sil, aS shown in HG. l, provides a concavely curved surface 34 which is associated with a convexly curved surface 35 provided bythe bottom of a generally cup-shaped member 3d. @ne end of a compression spring it? is seated in the cup-shaped member 3d and the other end thereof seated in a `socket il provided by the casing member l2. Accordensayos ingly, spring d@ resiliently biases contact member 3? against contacts Zal and 26.

The open end lof `casing member l2 is closed by a metallic heat conductive cup member which may be spun or otherwise turned in about its periphery as at 4d to secure it to casing member l2. Disposed within cup 1d is a thermally responsive snap-acting disc or element Sti. As best seen in FlG. l the outer annular marginal periphery of thermally responsive element 541i is engaged with and supported by `an interior step of cup ld and is supported in intimate, direct heat conductive or heat transfer relation to cup Disc 5d may be of the bimetallic type as shown and described in United States Patent No. 1,448,- 240 to I. A. Spencer issued March 13, 1923. Disc 5d as shown in FIG. l is in a downwardly bowed condition. In response to a predetermined ambient temperature change disc Si? will snap to an upwardly bowed condition of opposite configuration. A motion transfer member 52 is slidably received Iand guided for reciprocal vertical movement (as seen in FIG. 1) by opposed recesses Sd provided by casing member 12. Une end Se' of motion transfer member 52 is disposed in abutment with a central portion of disc 5@ and the other end thereof provides a dat surface 5h disposed adjacent the bridging contact member Ell. The upper portion of member 52 is bifurcated and provides a pair of legs dit (only one of which is shown in FIG. l) which are .received within `suitable recesses provided in bridging contact member 3d.

When disc 5@ snaps to the upwardly bowed shape in response to a predetermined temperature change, it quickly moves motion transfer member 52 and the bridging contact member Sil upwardly (as seen in FlG. l) 4against the resilient bias of spring d@ to separate contact member .30 from the spaced contacts 24 and Z6 to open the circuit through switch ld. When discs 5d snaps back to the configuration shown in FIG. 1 in response to a temperature change in the opposite direction, it permits contact member 3d and motion transfer member 52 to return quickly to the contacts-closed condition under the bias of spring fill.

Cup 1li is provided with a pair of annularly or circumtferentially extending lip portions 7l) formed integrally therewith and a pair of spaced radially projecting tab portions 72 which may be struck out from and formed integrally with cup 11d. As best seen in FlG. 3 projecting tabs '72 are spaced from Vand disposed at an angle to circumferentially extending and projecting lip portions 7l). As seen in FlG. 3, one edge 7d of tabs '72 is spaced a distance Y from lip 7d while the other edge 76 thereof is spaced la distance Z from lip 7d, the distance Y being greater i than the distance Z.

In FlGS. l and 2 is shown one example of a flange generally designated at du which may be employed with and detachably connected to switch lil vfor mounting the switch on a support 82. Flange f5@ is adapted to mount the switch lll with the snap-acting disc Sil thereof in thermal juxtaposition to a substance or something, whose temperature is to be sensed, for example, a flow of air, where the switch l@ is employed in a clothes dryer application, or to sense the temperature of a liquid, for example, in a laundry machine application. As best seen in FlG. 2, mounting flange or bracket il@ includes a plurality of eared portions 84 each having a bolt receiving aperture do for the reception of bolts SS which co-operate with nuts @il to mount the flange on support 82 as shown in FIG. l. -Flange 3h is provided with a central plate-like body portion 92 having a thickness Y as shown (see FIG. 1). Portion 92 provides a centrally located aperture 9dfor receiving at least a portion of casing member 1d. The opening 9d is sufficiently larger than the portion of casing 14 to be received or accommodated therein to provide a thermal barrier to impede heat transfer between the flange till and casing 11i or disc 5t. Portion 92 of flange till further includes a pair of diametrically spaced, radially projecting slots or openings 95 which communicate with opend ing 9d and are adapted to receive and permit tabs 72 to be inserted therethrough.

From the above it will be seen that switch lll can be quickly and easily detachably firmly locked or secured to mounting flange Sli merely by inserting switch t@ into the opening @it with tabs 72 inserted through openings 9d, and thereafter, rotating switch l@ relative to flange dit so that the central body portion 92. around the opening 9d will be tightly received and gripped between lips 7b and tabs 72. in this condition, corner 76 of angularly disposed tabs 72 will resiliently and wedgingly engage and bite into the underside of the central body portion 92 (around opening 9d) to tightly secure the parts together and inhibit undesired and unintentional rotation between the par-ts in at least one direction which could result in separation of thc parts for example due to vibration. The invention is par- 'cularly useful for (though not limited to) replacement parts in that it eliminates the necessity for retaining large inventories of specially designed and configured mounting bracket thermos-tat constructions for long periods of time. To replace an earlier type thermostat construction, it is now only ynecessary to ysupply the required type mounting flange and to detachably connect i-t to a standard type thermostat, having the required rating, thus providing maximum application flexibility.

Another advantage of the construction of the present invention over that of the former integral mounting flangetype switch construction is that with the detachable flange arrangement less heat is conducted away from the thcrv.mally responsive member' Sli than with the former type integral construction, thereby providing greater elciency and sensitivity of operation for the thermally responsive switch lil.

The FGS. 1-3 embodiment also provides another advantage over the conventional integral flange switch constructions in affording flexibility and versatility for orienting terminals ld and l with respect to flange Sti, to meet specific requirements of particular applications. Since tabs 72 will wedgingly interlock switch il@ to flange Sti in any one of a variety of positions, switch lll can yadvantageously by rotated with respect to flange Sii until desired orientation and alignment of terminals lo and 18 is eected. Tabs 72 lwill thereafter maintain switch l@ detachably interlocked to ilange il@ in the adjusted position.

Referring now to FIGS. 4 and 5, there is shown a second embodiment according to the present invention. ln this regard those parts of the modified arrangement in FlGS. l and 5 which have primed reference numerals are or may be identical with their respective counterparts in FIGS. 1 3, having the same but unprimed reference numerals. in the FIGS. 4 and 5 embodiment the mounting flange lil@ comprises a flat washer-like member which is provided with an opening 19d for receiving a portion of casing 14 of switch lill. Flange 1351i also includes a pair of diametrically spaced radially projecting slots 1% which communicate with opening 19d and are arranged for registering with and permitting radially projecting tabs 72 to be inserted therethrough. Casing member 14 is provided with a pair of peripherally and circumferentially extending lip portions ltl which are generally similar to lip portions 7d of switch ld, except that in the FGS. 4-5 embodiment, lip portions 17d extend or project radially outwardly far enough so as to completely seal opening 194 and slots 11% when the switch lil is detachably locked to flange 18@ in the manner described above for switch l@ and flange Sti', the locked, rotated position being shown in FlG. 5. Lip portion 170 as shown in the detachably interlocked condition in FIG. 5, advantageously tightly seals openings 19d and slots M6. This construction is particularly useful for clothes dryer equipment applications where it is necessary to prevent the passage of lint from one side of the flange through to the other side, and also for laundry equipment applications where it is necessary to provide a watertight closure between the control and the flange. Flange ld, like flange sheaves 80, also includes a plurality of mounting ears 84 each of which includes bolt receiving apertures S6 for mounting the switch 1t) on a support such vas 82 (shown in FIG. 6) which has an opening 83 through which switch 10 extends or projects and can be mounted in thermally conductive juxtaposition to a substance whose temperature is to be sensed. The FIGS. 4-5 embodiment allords substantially all of the advantages of the FlGS. 1 3 embodiment described above.

Illustrated in FlG. 6 is a third embodiment of the invention in which those parts having double primed reference numerals are or may be identical with their respective counterparts in FlGS. 1 3 and 4-5 having the same but primed or unprimed reference numerals. The FIG. 6 embodiment differs mainly from the FGS. 4-5 embodiment in the provision of a gasket or sealing member 198 intermediate lip portions i'tl and tlange 13u as shown. Gasket member' 19S is ring like in form and is preferably formed of a llexible, deformable, thermally insulating material which serves to further minimize the -amount of heat which can be conducted away from the thermal element 50 by the flange ld, as well as to provide a positive watertight and air or lint-tight seal between the switch lil and the tiange 18d. Gasket M3 may be made of a suitable compressible brous material or a rubber-like material such as, for example, silicone rubber. The FIG. 6 embodiment affords substantially all of the advantages described -above for the FlGS. 1 3 embodiment, in addition to the advantages aorded by the sealing gasket or washer member 1%8.

Referring now to FlGS. 7 and 8, there is illustrated a fourth embodiment of the present invention. Those -parts in the FIGS. 1-3 and FlGS. 7-8 embodiments having the same reference numerals are or may be substantially identical. The FIGS. 7-8 embodiment dii'iiers mainly frorn the FIGS. l-3 embodiment in the provision of stop means on the mounting flange 23d for limiting relative rotation between thermally responsive switch it? and the mounting flange or bracket in one direction. Flange 286 is provided with a pair of spaced downwardly extending abutment stop members Ztltl. Abutment members 205) may be diametrically opposed toward each other and are preferably arranged so that an imaginary line drawn therebetween intersects an imaginary line drawn between the slots 96. Stops 20) project downwardly far enough to engage tab members 72 to limit relative rotation between the switch l@ and flange 280 in one direction. Stops 2th) in co-operating with tabs provide a positive means for orienting `and aligning switch l with respect to flange 23h to orient and align the switch terminals i6 and 18 as may be required for -a particular application. Stops 2h@ co-operate to prevent any tendencies for unintentional relative rotation between the switch lill and the flange Zilli in one direction, which might take place due to vibration. Unintentional relative rotation between switch and ilange 280 in the other direction is prevented by the wedging engagement of corner 7d of tab 72 with the underside of llange 28h, as seen in FIG. 7. It will be understood that the relationship between stops 290 and slots 95 can be varied as desired to orient and align the terminals 16 and 18 as required for a particular application.

Referring now to FIGS. 9 and l0, there is shown two further embodiments of the present invention, each of which is applicable to each of the embodiments of FlGS. 1-3, 4-5 and 6. FIGS. 9 and l0 illustrate a developed inside edge of the mounting ange Sti', adjacent the switch receiving opening therein, looking in a direction, radially outwardly from the opening. In FlGS. 9 and 1S the flanges are respectively generally designated by numerals 380 and 48u. The circumferential inside surface dening the .switch receiving opening in each of llanges 33h and 486 are respectively designated at numerals Sill and 4.2i. The portion of flange Sti@ surrounding the s*v itch receiving opening therein according to the FIG. 9 embodiment is provided with a series of radial undulations providing a series of spaced arcuate shaped tab receiving pockets Sill along the underside thereof as shown. Tabs 372 have an arcuate shaped cross-sectional coniiguration and are adapted to mate and interit with the arcuate shaped pockets Slt). Tabs 572 co-operate with pockets 3l@ to advantageously prevent undesirable and unintentional rotation between the switch itl and ilange 335i in all directions which might otherwise tend to take place due to vibration. Further, terminals l5 and l of switch it? can quickly and easily be oriented and aligned to meet requirements for a particular application by rotating housing 1li until tabs 372 are seated in the proper pair of tab receiving pockets Siti. Flange 3S@ provides substantially all of the advantages of the FIG. 7 flange Z3@ and also further provides for greater versatility and exibility of application, since the terminal orientation may be varied as desired merely by rotating the switch itl with respect to flange 38) in either of two directions as shown by the arrow and dashed-line tab positions in FlG. 9.

ln the FlG. l0 embodiment the portion of flange 43h surrounding the switch l@ receiving opening is provided with a plurality of circumferentially spaced, radially extending notches 42@ which are adapted to receive edge 76 ot tab 72 to wedgingly receive and lock tab 72 and switch 1d against rotation relative to flange in the direction of the arrow shown in FIG. 10. Notches 429 in their co-operation with edge 76 of tab 72 provide substantially all of the advantages described above for the FIGS. 1 3 embodiment. In the FlGS. l3 embodiment relative rotation between switch itl and ilange 8l) (in the direction of the arrow in FIG. 10) is also limited by the biting and wedging engagement of the corner 76 of tab 72 with the underside of the lange Sti. However, the FlG. l0 arrangement provides a more deiinite and positive type of stop to inhibit this relative rotation.

lt will be understood that in both of the embodiments of FIGS. 9 and l0, the entire circumference of the area of the flange surrounding the switch receiving opening therein, need not be provided with the undulated pockets 3l@ or the notches 426 but that only a portion or portions thereof can be so provided, as desired within the purview of the invention.

From the above it can be seen that the present invention provides both versatility and economy, and avoids the necessity for stocking and manufacturing a new thermostat every time a different shaped mounting flange or configuration is required.

ln view of the above, it will be seen that the several objects of the invention are achieved, and other advantageous results attained.

It will be understood that the configuration of the mounting llanges shown in the drawings are for purposes of illustration only and that other congurations may be employed within the purview of the present invention.

As many changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings, shall be interpreted as illustrative and not in a limiting sense, and it is also intended that the appended claims shall cover all such equivalent variations as come within the true spirit and scope of the invention.

We claim:

l. ln combination: an electrical switch including a pair of electrical contacts and a thermally responsive member operatively connected to actuate said contacts; a hollow housing enclosing said contacts and thermally responsive member; support means for mounting said switch in thermal juxtaposition to something whose temperature is to be sensed; said support means including an opening receiving at least part of said housing which includes said thermally responsive member; said opening being suciently larger than required to accommodate said part of said switch housing to impede heat transaient/es fer between said support means and housing; and means detachably locking said housing to said support means.

2. in combination: an electrical switch including a pair of electricaly contacts and a thermally responsive member operatively connected to actuate said contacts; a cup-shaped housing enclosing said contacts and thermally responsive member, a portion of said housing being formed of thermally conductive material and supporting said thermally responsive member in heat conductive relation therewith, said housing portion including outwardly projecting lip portions and a spaced pair of outwardly projecting tabs spaced from said lip portions; a mounting liange for mounting said switch on a support in a thermal juxtaposition to a substance whose temperature is to be sensed; said iiange being formed separately from said switch and support and also being provided with a first opening receiving therein said portion of said housing, said iiange also including a pair of spaced openings communicating with said iirst opening for receiving the projecting tabs on said housing; said tabs being so spaced from said lip portions as to tightly receive therebetween, portions of said ange around said iirst opening, detachably locking said housing portion to said flange when said housing and tabs are respectively inserted through said irst and pair of openings and said housing is rotated with respect to said flange.

3. The combination as set forth in claim 2 and including a washer disposed intermediate said lip and flange closing and sealing said slots.

4. The combination as set forth in claim 3 and wherein said washer is formed of thermally insulating material.

5. The combination as set forth in claim 2 and wherein said lip portions project outwardly to such an extent as to cover and seal said pair of openings when said housing is detachably locked to said flange.

6. The combination as set forth in claim 2 and wherein said fiange includes abutment means engageable with said tabs to limit relative rotation between said housing and flange in one direction.

7. ln combination: an electrical switch including a pair of electrical contacts and a thermally responsive member operatively connected to actuate said contacts; a cup-shaped housing enclosing said contacts and thermally responsive member, a portion of said housing being formed of thermally conductive material and supporting said thermally responsive member in heat conductive relation therewith, said housing portion including outwardly projecting lip portions and a spaced pair of outwardly projecting tabs spaced from said lip portions; a mounting flange for mounting said switch on a support in a thermal juxtaposition to a substance whose temperature is to be sensed; said flange being formed separately from said switch and support and also being provided with a first opening receiving therein said portion of said housing, said flange also including a pair of spaced openings communicating with said rst opening for receiving the projecting tabs on said housing; said tabs being so spaced from said lip portions as to tightly receive therebetween, portions of said flange around said first opening, detachably locking said housing portion to said fiange when said housing and tabs are respectively inserted through said first and pair of openings and said housing ,is rotated with respect to said flange; said tabs being angularly disposed with respect to said lip CII portions whereby to wedgingly engage said flange when said housing and tabs are respectively inserted through said first opening and said pair of spaced openings and said housing is rotated with respect to said flange; said flange on the side thereof engaged by said tabs, being provided with a plurality of spaced notches around said first opening for engagement with said tabs to limit relative rotation between said housing and ange in one direction.

8. The combination as set forth in claim 2 and wherein said flange, on the side thereof engaged by said tabs, is provided with an undulating surfacev around said opening providing a plurality of tab receiving pockets.

9. The combination as set forth in claim 8 and wherein said tabs have an arcuate shaped cross-sectional coniiguration to mate and inter-lit with selected ones of said pockets.

10. ln combination: an electrical switch inclduing a pair of electrical contacts and a thermally responsive member operatively connected to actuate said contacts; a hollow housing enclosing said contacts and thermally responsive member; a plurality of interchangeable mounting iianges each for selectively mounting said switch on a support in thermal juxtaposition to something whose temperature is to be sensed; each of said plurality of anges being formed separately from said switch and support and each of said flanges having a plate-like portion provided with an opening therein selectively receiving therein at le st part of said housing; and means on said housing detachably locking said housing to one of said flanges and said interconnection between said housing and flange impeding heat transfer' therebetween.

1l. in combination: an electrical switch including a pair of electrical contacts and a thermally responsive member operatively connected to actuate said contacts; a cup-shaped housing enclosing said contacts and thermally responsive member, a portion of said housing being formed of thermally conductive material and supporting said thermally responsive member in heat conductive relation therewith; said housing portion having projecting lip portions; a plurality of interchangeable mounting anges each selectively adapted to mount said switch on a support in thermal juxtaposition to something whose temperature is to be sensed; each of said plurality of mounting iianges being formed separately from said switch and support and each being provided with an opening selectively receiving therein said portion of said housing with said lip portions bearing against one side of the ilange around said opening; said opening in each of said plurality of flanges being suiciently larger than required to accommodate said switch housing portion whereby to impede heat transfer between said support and housing portion and means detachably locking said housing to one of said flanges.

Reterences Qited in the file of this patent UNTED STATES PATENTS 2,093,038 Douglas Sept. 14, 1937 2,562,390 Popp iuly 3l, 1951 2,814,7@2 Mucher NOV. 26, 1957 2,885,905 Larkin May 12, 1959 2,907,851 Moorhead et al. Oct. 6, 1959 FORElGN PATENTS 1,193,016 France Oct. 29, 1959 

1. IN COMBINATION: AN ELECTRICAL SWITCH INCLUDING A PAIR OF ELECTRICAL CONTACTS AND A THERMALLY RESPONSIVE MEMBER OPERATIVELY CONNECTED TO ACTUATE SAID CONTACTS; A HOLLOW HOUSING ENCLOSING SAID CONTACTS AND THERMALLY RESPONSIVE MEMBER; SUPPORT MEANS FOR MOUNTING SAID SWITCH IN THERMAL JUXTAPOSITION TO SOMETHING WHOSE TEMPERATURE IS TO BE SENSED; SAID SUPPORT MEANS INCLUDING AN OPENING RECEIVING AT LEAST PART OF SAID HOUSING WHICH INCLUDES SAID THERMALLY RESPONSIVE MEMBER; SAID OPENING BEING SUFFICIENTLY LARGER THAN REQUIRED TO ACCOMMO- 